JP2010208206A - Method for laminating ceiling material and ceiling material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for laminating a ceiling material in a method for manufacturing the interior ceiling material of an automobile, in which the ceiling material is obtained by laminating a surface material on both surfaces of a core material, the core material is a plate material made of a polymer resin foam, a copolymerized polyester film adhesive material is held between the core material and the surface material and then lamination by thermal pressing is carried out to compatibly attain weight reduction and adhesiveness improvement. <P>SOLUTION: In the method for laminating the ceiling material, the surface material is laminated on one surface or both surfaces of the core material, the core material is the plate material made of the polymer resin foam, the copolymerized polyester film adhesive material is held between the core material and the surface material and then lamination by thermal pressing is carried out. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an interior ceiling material used as an interior material of a roof of an automobile body.

  Automotive interior ceiling materials are used to absorb external noise and improve the thermal insulation of automobiles. In general, they have good heat resistance, thermal insulation and shape stability, and improve automobile fuel efficiency. For this reason, it has been necessary to use lightweight materials.

Conventionally, as a ceiling material, a melted high-density polyethylene or low-density polyethylene is used as a core material as a method of bonding a nonwoven fabric such as polyester fiber or a fabric or a plastic sheet (skin material) to urethane foam (core material). A method of pasting while extruding in the middle of the skin material has been used.
However, in order to increase the adhesion between the core material and the skin material, it is necessary to increase the extrusion thickness of the molten resin, and the weight as the interior material increases, so a method for reducing the weight without reducing the adhesive strength is required. It was. Further, since different materials are used, it is difficult to obtain sufficient adhesion performance even if the molten resin is thickened.

  Therefore, in order to reduce the weight of the ceiling material, a method of thermocompression bonding via an olefin-based hot melt film is disclosed instead of laminating. For example, in Patent Document 1, as a conventional product, “a glass fiber mat is pasted on both sides of a urethane foam via an olefin-based hot melt film, and further a polyester nonwoven fabric is pasted via an olefin-based hot melt film. There is disclosure of “ceiling material”. However, when an olefin-based hot melt film is used, sufficient adhesive strength cannot be obtained without an appropriate film thickness. If the film thickness is increased to increase the adhesive strength, there is a problem that the weight of the ceiling material is increased. . On the other hand, the invention of Patent Document 1 discloses “ceiling material in which a polyester nonwoven fabric is bonded to both surfaces of a urethane foam via a polycarbonate film”, and certainly uses such a polycarbonate film. In such a case, the film thickness can be reduced to obtain adhesion performance. However, in order to melt the polycarbonate, it is necessary to perform heat treatment at a relatively high temperature, and the adhesion strength is relatively insufficient.

  Patent Document 2 discloses a ceiling material in which a nonwoven fabric is attached to both surfaces of a urethane foam via a styrene copolymer resin film. However, in any case, since a film made of a material different from polyester is used, the adhesive strength is weak and it is necessary to increase the thickness of the hot melt film.

  Patent Document 3 discloses a nonwoven fabric sheet for ceiling interior materials in which a polybutylene terephthalate resin is laminated on at least one side of a polyester nonwoven fabric. Polybutylene terephthalate melt-extrusion and simultaneous lamination of polyester nonwoven fabric enable adhesion with a small amount of extruded resin, which can reduce weight, but polybutylene terephthalate has high crystallinity and may peel off after lamination Yes, the adhesiveness was low.

JP-A-9-123323 JP 11-48876 A JP 2004-25522 A

  The present invention relates to a method for manufacturing a ceiling material for interiors of an automobile, which is a ceiling material obtained by laminating a skin material on both sides of a core material, the core material is a plate material made of a polymer resin foam, and the core material and the skin material An object of the present invention is to provide a method for laminating a ceiling material which is excellent in both weight reduction and adhesiveness by sandwiching a copolyester film adhesive material between them and thermocompression-bonding them.

  As a result of intensive studies to solve such problems, the present inventors are a ceiling material obtained by laminating a skin material on both sides of a core material, and the core material is a plate material made of a polymer resin foam. The inventors have found that the above object can be achieved by sandwiching a copolymer polyester film adhesive material between a core material and a skin material, and using a method of laminating a ceiling material that is laminated by thermocompression bonding.

  That is, the gist of the present invention is as follows.

(1) A method of laminating a ceiling material in which a skin material is laminated on one or both sides of a core material, wherein the core material is a plate material made of a polymer resin foam, and a copolyester film is bonded between the core material and the skin material A method for laminating a ceiling material, comprising sandwiching materials, thermocompression bonding, and laminating.
(2) The method for laminating a ceiling material according to (1), wherein the core material is urethane foam.
(3) The copolyester film adhesive material is made of a copolyester resin having a number average molecular weight of 10,000 or more and a melting point of 70 ° C. to 150 ° C., the content of the inorganic compound is 5% by mass or less, and the thickness is 25 to 200 μm. (1) The method for laminating the ceiling material according to (2).
(4) A ceiling material manufactured by the method of laminating a ceiling material according to (1) to (3).

  According to the present invention, a ceiling material obtained by laminating a skin material on both surfaces of a core material, the core material is a plate material made of a polymer resin foam, and a copolyester film adhesive material is provided between the core material and the skin material. By sandwiching, thermocompression bonding, and laminating, it is possible to provide a ceiling material laminating method that is excellent in both weight reduction and adhesiveness.

  Hereinafter, the present invention will be described in detail.

  First, the core material used in the ceiling material of the present invention will be described. As a core material to be used, a plate material made of a polymer resin foam that is lightweight and excellent in dimensional stability can be used. As the polymer resin to be used, a material that can be foam-molded can be appropriately selected, and in particular, an aromatic polyester resin, an aliphatic polyester resin, or a urethane resin can be selected. As the aromatic polyester resin, polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate are preferable, and as the aliphatic polyester resin, polylactic acid, polyethylene succinate, and polybutylene succinate are preferable. Moreover, as a urethane type resin, a polyurethane is preferable. Among them, urethane foam obtained by foaming polyurethane is most preferable because it has heat resistance that can withstand practical use up to 100 ° C. in addition to light weight and dimensional stability.

  The urethane foam used in the present invention will be described.

Urethane foam, preferably a density 20 and 100 kg / ^{m 3,} more preferably ^{25~40kg / m 3, 25~35kg / m} 3 being most preferred. If the density is less than 20 kg / m ^{3, the} thermal insulation required for the ceiling material is deteriorated, which is not preferable. If the density is higher than 100 kg / m 3, the weight increases, which is not preferable. The urethane foam can be obtained by reacting a polyisocyanate component and a polyol component. The polyol component may comprise a polyol, a catalyst and a foaming agent, and optionally a flame retardant, a viscosity reducing agent and a foam stabilizer. The urethane foam is preferably in the form of a sheet, and the thickness is preferably 3 to 8 mm. If the thickness is less than 3 mm, the mechanical properties are poor, which is not preferable. If the thickness is more than 8 mm, it is not preferable because it becomes heavy.

  Next, the skin material used for the ceiling material will be described. As the skin material to be used, a material having heat resistance, durability, and quality as an automobile interior material can be selected. As the material, polyester-based, nylon-based, natural fiber-based woven fabrics and non-woven fabrics can be selected. Among them, non-woven fabrics having excellent texture and shape stability can be used. As the material, a polyester-based nonwoven fabric represented by polyethylene terephthalate and a polylactic acid-based nonwoven fabric can be suitably used. However, the material is excellent in durability, and is bonded to the copolymerized polyester film adhesive material used in the ceiling material of the present invention. A polyester-based non-woven fabric having excellent properties and affinity is most preferable.

  The preferable nonwoven fabric used by this invention is demonstrated. In addition, the nonwoven fabric described below is an example of the present invention, and can be appropriately selected within a range not greatly deviating from the scope of use of the present invention.

  As the nonwoven fabric, a polyester nonwoven fabric composed of polyethylene phthalate resin fibers, or a nonwoven fabric composed of core-sheath composite fibers in which a core component is a polyethylene terephthalate resin and a sheath component is blended with a thermoplastic resin having a low melting point is used. Examples of the shape include known nonwoven fabrics such as a spunbond nonwoven fabric and a spunlace nonwoven fabric. Among these, a spunlace nonwoven fabric is preferable because a nonwoven fabric excellent in shape stability and strength can be produced by entanglement of fibers.

  In the case of a nonwoven fabric composed of core-sheath composite fibers, a general-purpose thermoplastic resin having a melting point of the sheath component resin of 40 ° C. or more lower than that of the core component resin can be used. A non-woven fabric made of core-sheath composite fibers becomes a non-woven fabric having a three-dimensional structure by being manufactured at a temperature of about 180 ° C to 230 ° C.

The fiber length of the fiber used for the nonwoven fabric is preferably 15 to 100 mm in both cases where a single fiber and a core-sheath composite fiber are used. Shorter or longer than this range is not preferable because it makes it difficult to pass the short fiber through the card. The cross-sectional shape of the fiber forming the nonwoven fabric is not particularly limited, and known ones such as a circle, a triangle, and a flat shape can be used. The fineness of the fibers forming the nonwoven fabric is preferably 0.3 to 3.5 dtex. If the fineness is smaller than 0.3 dtex, it is not preferable because the manufacturing process becomes difficult and the cost is increased by the ordinary melt spinning method. If the fineness is larger than 3.5 dtex, the heat insulating property required for the ceiling material is insufficient. Since it falls, it is not preferable. The basis weight of the nonwoven fabric is preferably 15 to 200 g / m ² . If the basis weight is less than 15 g / m ^2, the density is lowered, unpreferably insulation resistance is reduced, since the basis weight becomes heavier and larger than 200 g / m ² is not preferable.

  Next, the copolyester resin used for the copolyester film adhesive material used in the present invention will be described.

  The number average molecular weight of the copolyester resin needs to be 10,000 or more, and preferably 15,000 or more. When the molecular weight is less than 10,000, the adhesion strength to the adherend is lowered, which is not preferable. In addition, since the melt viscosity becomes too low, the film is easily broken during film formation, and film formation becomes difficult.

  The melting point (hereinafter abbreviated as Tm) of the copolyester resin is required to be 70 to 150 ° C., and preferably 70 to 120 ° C. If Tm is higher than 150 ° C., the temperature must be set high when bonding, which is not only economically expensive, but depending on the base material, heat shrinkage and use are limited, which is not preferable. Moreover, when it is lower than 70 degreeC, since the operativity at the time of pelletizing a copolyester resin and polyester film formation may be impaired, it is unpreferable.

  The glass transition point (hereinafter abbreviated as Tg) of the copolyester resin is preferably -30 to 20 ° C. If Tg exceeds 20 ° C., the temperature must be set high when bonding, and depending on the material, the adherend cannot be used due to heat shrinkage, which is not preferable. Moreover, when Tg is less than −30 ° C., the operability at the time of pelletizing the copolymer polyester resin or at the time of forming the polyester film may be unfavorable.

  The number average molecular weight of the copolyester resin can be adjusted to the above range by controlling the polymerization time and the depolymerization amount, and Tm and Tg can be adjusted to the above ranges by setting the combination of monomers to be copolymerized. .

  Next, the composition of the copolyester resin will be described.

  The copolyester resin is a resin mainly composed of equimolar amounts of a dicarboxylic acid component and a glycol component.

  Dicarboxylic acid components include terephthalic acid, isophthalic acid, phthalic anhydride, naphthalene dicarboxylic acid, aromatic dicarboxylic acids such as 4,4'-dicarboxybiphenyl, 5-sodium sulfoisophthalic acid, oxalic acid, malonic acid, succinic acid , Saturated aliphatic dicarboxylic acids such as adipic acid, azelaic acid, sebacic acid, undecanedioic acid, dodecanedioic acid, octadecanedioic acid, and aicosanedioic acid, fumaric acid, maleic anhydride, itaconic acid, mesaconic acid, citraconic acid, etc. Unsaturated aliphatic dicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanedicarboxylic acid, 2,5-norbornenedicarboxylic acid, alicyclic dicarboxylic acid of tetrahydrophthalic acid or ester thereof Examples thereof include formable derivatives.

  Among these dicarboxylic acid components, terephthalic acid, isophthalic acid, adipic acid, sebacic acid, and 1,4-cyclohexanedicarboxylic acid are preferred because of their versatility. These ratios are selected so that the melting point and glass transition point of the copolyester resin fall within the ranges defined in the present invention.

Examples of the glycol component include ethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,3-butanediol, 1,4-butanediol, and 2-methyl-1,3. -Propanediol, 2,2-diethyl-1,3-propanediol, 2-amino-2-ethyl-1,3-propanediol, 2-amino-2-methyl-1,3-propanediol, 2-ethyl 2-methyl-1,3-propanediol, 2-butyl-2-ethyl-1,3-propanediol, neopentyl glycol, 3-methyl-1,5-pentanediol, 1,5-pentanediol, 1 , 6-hexanediol, 1,7-heptanediol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol, 3 (4 ), 8 (9) -bis (hydroxymethyl) -tricyclo (5.2.1.1/2.6) decane, diethylene glycol, triethylene glycol,
Aliphatic glycols such as dipropylene glycol and tripropylene glycol, bisphenol A, bisphenol S, bisphenol C, bisphenol Z, bisphenol AP, ethylene oxide adduct or propylene oxide adduct of 4,4'-biphenol, 1,2-cyclohexane Examples include alicyclic glycols such as dimethanol, 1,3-cyclohexanedimethanol, 1,4-cyclohexanedimethanol, and isosorbide, polyethylene glycol, and polypropylene glycol.

  Among these glycol components, ethylene glycol, 1,2-propanediol, 1,4-butanediol, neopentyl glycol, ethylene oxide adduct of bisphenol A, and 1,4-cyclohexanedimethanol are versatile and preferable. . These ratios are selected so that the melting point and glass transition point of the copolyester resin fall within the ranges defined in the present invention.

  In the copolymerized polyester resin, a hydroxycarboxylic acid can be used as a copolymerization component in accordance with purposes such as appropriate flexibility, improved adhesion, and adjustment of the glass transition point. As the hydroxycarboxylic acid, an ethylene oxide adduct of p-hydroxybenzoic acid, an ethylene oxide adduct of m-hydroxybenzoic acid, an ethylene oxide adduct of o-hydroxybenzoic acid, lactic acid, oxirane, β-propiolactone, β-butyrolactone, γ-butyrolactone, δ-valerolactone, ε-caprolactone, glycolic acid, 2-hydroxybutyric acid, 3-hydroxybutyric acid, 4-hydroxybutyric acid, 2-hydroxyisobutyric acid, 2-hydroxy-2-methylbutyric acid, 2-hydroxyyoshi Examples include valeric acid, 3-hydroxyvaleric acid, 4-hydroxyvaleric acid, 5-hydroxyvaleric acid, 6-hydroxycaproic acid, 10-hydroxystearic acid, and the like.

  Of these hydroxycarboxylic acids, ε-caprolactone is preferred because of its versatility. These ratios are selected so that the melting point and glass transition point of the copolyester resin fall within the ranges defined in the present invention.

  If it is a small amount, a tri- or higher functional carboxylic acid component or alcohol component may be added to the copolymer polyester resin as a copolymer component. Examples of the tri- or higher functional carboxylic acid component include aromatics such as trimellitic acid, pyromellitic acid, benzophenone tetracarboxylic acid, trimellitic anhydride, pyromellitic anhydride, benzophenone tetracarboxylic acid anhydride, trimesic acid, and the like. Examples thereof include carboxylic acids and aliphatic carboxylic acids such as 1,2,3,4-butanetetracarboxylic acid.

  Examples of the tri- or higher functional alcohol component include glycerol, trimethylolpropane, trimethylolethane, pentaerythritol, α-methylglucose, mannitol, and sorbitol.

  These do not necessarily need to be used alone, and can be used in combination of two or more according to the properties desired to be imparted to the resin. At this time, the proportion of the tri- or higher functional monomer is suitably about 0.2 to 5 mol% with respect to the total carboxylic acid component or the total alcohol component. If the amount added is less than 0.2 mol%, the added effect does not appear, and if the amount exceeds 5 mol% is included, the gelation may exceed the gel point during polymerization.

  Moreover, monocarboxylic acid and monoalcohol may be copolymerized with the copolyester resin. Examples of monocarboxylic acids include lauric acid, myristic acid, palmitic acid, stearic acid, oleic acid, linoleic acid, linolenic acid, benzoic acid, p-tert-butylbenzoic acid, cyclohexane acid, 4-hydroxyphenyl stearic acid, and the like. Examples of the alcohol include octyl alcohol, decyl alcohol, lauryl alcohol, myristyl alcohol, cetyl alcohol, stearyl alcohol, and 2-phenoxyethanol.

  Copolyester resin can be manufactured by combining the said monomer and carrying out polycondensation by a well-known method. For example, all monomer components and / or low polymers thereof are reacted at 180 to 250 ° C. for about 2.5 to 10 hours under an inert atmosphere to carry out an esterification reaction, followed by 220 to 220 under a reduced pressure of 130 Pa or less. A method in which the polycondensation reaction is allowed to proceed until a desired molecular weight is reached at a temperature of 280 ° C. can be mentioned.

  In the esterification reaction and polycondensation reaction, germanium compounds such as germanium dioxide, titanium compounds such as tetrabutyl titanate, metal acetates such as zinc acetate and magnesium acetate, antimony trioxide, hydroxybutyltin oxide, Polymerization is performed using an organic tin compound such as tin octylate. The amount of catalyst used at that time is usually 0.5% by mass or less based on the resin to be produced.

  In addition, when a desired acid value or hydroxyl value is imparted to the copolymerized polyester resin, a polybasic acid component or a polyvalent glycol component is further added following the polycondensation reaction, and depolymerization is performed in an inert atmosphere. To do.

  Next, the manufacturing method of the copolyester film adhesive material of this invention is demonstrated. The copolyester film adhesive material can be produced from the above copolymer polyester resin by a known film forming method such as an inflation method, a film forming method using a T-die, or an extrusion laminating method.

  As the inflation method, the dried copolyester resin is put into an extruder, and the molten resin is pulled up from a circular die into a tube shape, and then air-cooled and simultaneously inflated into a balloon shape to form, fold, and form a cylindrical film with a nip roll. A method of heat-sealing and winding it up, or by extruding the molten resin into a cylindrical shape from a circular die downward in the cooling water, folding it, heat-sealing the cylindrical film with a nip roll, and scraping it off A method is mentioned.

  In the case of using a resin having a low Tg, it is preferable that a release paper is sandwiched between the films when the films are scraped, since blocking after scraping can be prevented.

  Examples of the film forming method using a T die include a method in which a dry copolymerized polyester is put into an extruder, a molten resin is extruded from the T die, and wound up.

  As in the inflation method, when a resin having a low Tg is used, it is preferable that a release paper is sandwiched between the films when the films are scraped, so that blocking after scraping can be prevented.

  Examples of the extrusion laminating method include a method in which a dry copolymerized polyester resin is put into an extruder and a molten resin is extruded from a T die onto a support film.

  The release paper used for the film forming method using the inflation method and the T-die, and the support film used for the extrusion laminating method can be arbitrarily selected as long as they are films that peel from the resin. However, when used as a support film for extrusion lamination, it is necessary to select a support film having a melting point higher than the melting temperature. Examples of these films include polyethylene film, polypropylene film, polyethylene terephthalate film, and paper whose surface has been subjected to mold release treatment, and polypropylene film is preferable because it is inexpensive and has a relatively high melting point.

  In any film forming method, the screw diameter of the extruder is appropriately selected, and the polymer melting temperature is appropriately selected within a temperature range of Tm + 100 ° C. or less. Further, the discharge amount of the resin is appropriately selected depending on the balance between the cooling rate and the discharge amount.

  In addition, you may extend | stretch, after winding up the copolyester film adhesive material used for this invention.

The thickness of the copolymerized polyester film is preferably 25 to 200 μm, more preferably 25 to 150 μm, and further preferably 25 to 100 μm.
When the thickness of the film adhesive material exceeds 250 μm, it becomes undesirably heavy when used as a ceiling material. If the film adhesive material is thinner than 25 μm, it is not preferable because sufficient adhesive strength cannot be obtained.

  Moreover, when using a copolyester film as a film adhesive material, a plurality of sheets may be used in an overlapping manner. However, it is not preferable to superimpose more than necessary because the weight of the ceiling material increases. Although it depends on the thickness per copolymerized polyester film, the thickness of the final film adhesive material is preferably 25 to 200 μm, more preferably 25 to 150 μm, even when it is used in a superimposed manner, 50 to 100 μm. Is more preferable.

  The copolymerized polyester film adhesive material of the present invention may contain an inorganic compound, and its content is preferably 5% by mass or less, and more preferably 3% by mass or less. By containing an inorganic compound, blocking of the films can be suppressed, and by improving sliding, not only can the wrinkles of the film adhesive material be reduced, but also the effect of preventing the above-described fusion at the time of scraping. is there. On the other hand, if the content of the inorganic compound exceeds 5% by mass, film formation may be difficult, and physical properties of the obtained film adhesive material, particularly heat seal strength, may be significantly reduced, causing a problem in practical use. This is not preferable.

  Examples of the inorganic compound include talc, silica, calcium carbonate, magnesium carbonate, kaolin, mica, titanium oxide, aluminum oxide, zeolite, clay, and glass beads. Of these, silica and magnesium carbonate are preferred because of their versatility. In the case of adding an inorganic compound, it is preferable to use master pellets prepared in advance by melt-kneading and compounding a copolymerized polyester and an inorganic compound with a twin-screw extruder.

  Various additives, antioxidants, ultraviolet absorbers, light stabilizers, antistatic agents, pigments, flame retardants and the like may be added to the polyester nonwoven fabric and copolymer polyester film used in the present invention.

  The ceiling material of the present invention is a ceiling material in which a skin material is laminated on one or both sides of a core material, the core material is a plate material made of a polymer resin foam, and a copolymerized polyester film between the core material and the skin material It is characterized by sandwiching an adhesive material, thermocompression bonding, and laminating. As a method of laminating the ceiling material, a copolyester film adhesive material is placed on one side of a core material prepared in advance, and a skin material is further stacked, and sandwiched by pressurizing or heating in an oven or a press machine. The copolymerized polyester resin melted by melting the copolymerized polyester film adhesive material and permeating the core material and skin material, and then cooling at room temperature after taking out from the press machine or at room temperature. Is cooled and solidified to obtain strong adhesiveness. Moreover, a skin material can be similarly laminated | stacked also on the opposite surface of a core material as needed.

  The copolyester film adhesive material used in the present invention has a sufficiently low glass transition temperature because the copolyester resin used as a film adhesive material has a sufficiently low glass transition temperature, and the embrittlement of the adhesive material due to temperature changes in the automobile interior. Deterioration hardly occurs and peeling of the adhesive interface between the core material and the skin material hardly occurs.

  As specific conditions for lamination, the oven temperature and time are appropriately selected depending on the urethane foam, copolymerized polyester film, and polyester nonwoven fabric to be used as long as they are lower than the melting point of the urethane foam and polyester nonwoven fabric to be used. be able to. For example, the oven temperature can be set to 70 ° C. to 150 ° C., and the heating time can be set to 10 to 120 seconds.

  In the case of pressurization, it can be appropriately selected as long as the shape of the urethane foam is maintained and bonded. Among these, 0.5 to 3 MPa is most preferable because the shape does not collapse and the adhesiveness is good.

  The present invention will be specifically described below with reference to examples.

1. Raw materials used (1) Urethane foam / urethane foam (thickness 6 mm, density 30 kg / m ³ )
(2) Nonwoven fabric / polyester spunlace nonwoven fabric (fiber length 30 mm, fineness 3 dtex,
(Weight weight 50g / m ² , thickness 30μm)

2. Measurement method (1) Fiber length of nonwoven fabric It was measured according to JIS L1015 (1999) 8.4.1.
(2) Fineness of nonwoven fabric It measured according to JIS L1015 (1999) 8.5.1.
(3) Fabric weight of nonwoven fabric It was measured according to JIS L1096 (1999) 8.4.2.
(4) Thickness of nonwoven fabric It measured according to JIS L1096 (1999) 8.5.1.
(5) Density of urethane foam It measured according to JIS K6400 (2004) "apparent density".
(6) Thickness of urethane foam It measured according to JIS K6400 (2004) 6.
(7) Number average molecular weight of copolymerized polyester resin The number average molecular weight is determined by GPC analysis (liquid feeding unit LC-10ADvp type and UV-visible spectrophotometer SPD-6AV type manufactured by Shimadzu Corporation), detection wavelength: 254 nm, solvent : Tetrahydrofuran, polystyrene conversion).
(8) Tm and Tg of copolymer polyester resin
Using a copolymerized polyester 10 mg as a sample, a DSC (Differential Scanning Calorimetry) device (DSC7 model manufactured by PerkinElmer Co., Ltd.) is used to measure at a temperature rising rate of 10 ° C./min. The peak temperature of the endothermic peak in the 1st scan Was defined as Tm, and an intermediate value between two bending point temperatures derived from the glass transition in the temperature rise curve of the 2nd scan was defined as Tg.
(9) Composition of copolymer polyester resin
^{It determined by 1} H-NMR analysis (manufactured by Varian, 300 MHz).
(10) Copolymerized polyester film adhesive material thickness and copolymerized polyester resin thickness Measurements were made using a HEIDENHAIN thickness measuring device.
(11) Maximum bending load, bending elastic gradient At 23 ° C. and 80 ° C., using an Intesco precision universal material testing machine 2020, a 50 × 150 mm test piece was loaded from the upper surface of the test piece at a speed of 50 mm / min. And the maximum value of the bending load was taken as the maximum bending load, and the tangent on the chart at the time of 1 cm deflection was taken as the bending elastic gradient.
(12) Adhesive strength When using a copolyester film material, the copolyester film material is laminated between a urethane foam and a polyester nonwoven fabric, and a pressure of 8.5 kgf / cm2 is applied for 30 seconds at an arbitrary temperature. Hot compressed.

  Thereafter, the adhesive strength was measured using a precision universal material testing machine 2020 manufactured by Intesco under an atmosphere of a temperature of 20 ° C. and a humidity of 50%. 10 N / 20 mm or more was determined to be acceptable (◯), and less than 10 N / 20 mm was determined to be unacceptable (x).

(Manufacture of copolyester resin)

Production Example 1
A mixture comprising 997 g (60 mol parts) of terephthalic acid, 809 g (40 mol parts) of sebacic acid, 434 g (70 mol parts) of ethylene glycol, 712 g (79 mol parts) of butanediol, and 100 g (1 mol part) of polytetramethylene glycol 1000 While stirring, the mixture was heated at 240 ° C. for 3 hours in an autoclave to carry out an esterification reaction. Subsequently, while maintaining the temperature at 240 ° C., 2.0 g of tetrabutylentitanate was added as a catalyst, the pressure of the system was gradually reduced to 13 Pa after 1.5 hours, and a polycondensation reaction was performed. Polycondensation was performed until the viscosity reached an appropriate level, and the resin was discharged into a sheet. After the sheet was crystallized at 80 ° C. for about 2 hours, 3 mm cubic rectangular copolyester resin 1 pellets were obtained using a die cutter. Table 1 shows the final resin composition and characteristic values of the obtained pellets.

Production Examples 2-6
The monomer used and the charged molar part were changed, and the same operation as in Production Example 1 was performed to obtain copolymer polyester resins 2 to 6. Table 1 shows the final resin composition and characteristic values of the obtained copolyester resins 2 to 6.

(Manufacture of adhesive material for copolymerized polyester film)

Production Example 7
The pellets of the copolyester resin 1 are sufficiently dried, and further, the pellets of the copolyester resin 1 are put into an extruder, and the molten resin is removed from the T-die with a release film (polypropylene film, manufactured by Tosero Co., Ltd., 50 μm). Extruded up. Thereafter, the film was scraped by 100 m with a scraper to obtain a copolymerized polyester film adhesive material (a). The screw diameter of the extruder was 65 mm, the polymer melting temperature was 140 ° C., the lip of the T die was 400 mm, the lip gap was 1 mm, and the scooping rollers were all textured. The obtained film adhesive material (a) had a thickness of 50 μm and a film width of 250 mm. Table 2 shows the resin used, the film forming method, and the characteristic values of the obtained film.

Production Example 8
A film adhesive material (b) was produced in the same manner as in Production Example 7 except that the type of copolymer polyester resin and the polymer melting temperature were changed. Table 2 shows the resin used, the film forming method, and the characteristic values of the obtained film.

Production Example 9
99% by mass of the sufficiently dried pellets of the copolymerized polyester resin 3 and 1% by mass of an inorganic compound (Silo Hovic 702 manufactured by Fuji Silysia) were charged into a twin-screw extruder, sufficiently kneaded, and then discharged into a sheet. After the sheet was crystallized at 80 ° C. for about 2 hours, compound pellets of 3 mm cubic rectangular copolyester resin 3 were obtained using a die cutter. The polymer melting temperature was 155 ° C.

  Thereafter, the pellets were sufficiently dried and then put into an extruder, and the melted resin was expanded from a circular die by air pressure, and at the same time air-cooled by an air ring, formed into a tubular film and pulled up. The tube-shaped film is taken up by a pair of pinch rolls installed at the top of the die, heat-sealed on the inner surface, and a release film (polypropylene film, manufactured by Tosero Co., Ltd., 50 μm) is attached as it is, A co-polyester film adhesive material (c) was obtained by scraping 100 m with a scraper. The screw diameter of the extruder was 65 mm, the polymer melting temperature was 155 ° C., the diameter of the circular die was 150 mm, and the lip gap was 4 mm. The obtained film adhesive material (c) had a thickness of 250 μm and a film width of 420 mm. Table 2 shows the resin used, the film forming method, and the characteristic values of the obtained film.

Production Example 10
A film adhesive material (d) was produced in the same manner as in Production Example 7 except that the type of copolymer polyester resin and the polymer melting temperature were changed. Table 2 shows the resin used, the film forming method, and the characteristic values of the obtained film.

Production Example 11
A film adhesive material (e) was produced in the same manner as in Production Example 7 except that the type of copolymer polyester resin and the polymer melting temperature were changed. Table 2 shows the resin used, the film forming method, and the characteristic values of the obtained film.

Production Example 12
A film adhesive material (f) was tried to be produced in the same manner as in Production Example 7 except that the type of copolymer polyester resin and the polymer melting temperature were changed, but the film could not be produced due to severe blocking.

Example 1
A copolyester film adhesive material (a) having a thickness of 50 μm is laminated on one surface of a urethane foam having a thickness of 6 mm and a density of 30 kg / m ³ , and further, a fiber length of 30 mm, a fineness of 3 dtex, and a basis weight of 50 g. A polyester spunlace nonwoven fabric having a thickness of 30 μm / m ² was laminated and pressed into an oven heated to 150 ° C. for 30 seconds to be molded. Similarly, a copolymerized polyester film and a polyester spunlace nonwoven fabric were laminated on the other side. Then, it pressurized and shape | molded in the shape of the desired ceiling material. Table 3 shows the adhesive strength, the weight of the adhesive, and the appearance of the ceiling material as indicators of the maximum bending load, bending elastic gradient and adhesive strength, which are typical mechanical characteristic values.

Examples 2-5
A ceiling material was molded in the same manner as in Example 1 except that the copolymerized polyester film was changed. Table 3 shows the adhesive strength, the weight of the adhesive, and the appearance of the ceiling material as indicators of the maximum bending load, bending elastic gradient and adhesive strength, which are typical mechanical characteristic values.

Comparative Examples 1 and 2
On one side of urethane foam with a thickness of 6 mm and a density of 30 kg / m ³ , low-density polyethylene is extruded at 130 ° C. with a thickness of 400 μm and 50 μm, respectively, and further, a fiber length of 30 mm, a fineness of 3 dtex, and a basis weight of 50 g A polyester spunlace nonwoven fabric having a thickness of 30 μm / m ² was laminated and pressed into an oven heated to 150 ° C. for 30 seconds to be molded. Similarly, a copolymerized polyester film and a polyester spunlace nonwoven fabric were laminated on the other side. Thereafter, it was tightly pressed and formed into a desired ceiling material shape. Table 4 shows the maximum bending load, bending elastic gradient and adhesive strength, the weight of the adhesive part, and the appearance of the ceiling material.

Comparative Examples 3-5
A ceiling material was produced in the same manner as in Example 1 except that the thickness of the copolyester adhesive material and the film was changed. Table 4 shows the maximum bending load, bending elastic gradient and adhesive strength, the weight of the adhesive part, and the appearance of the ceiling material.

Comparative Example 6
A ceiling material was produced in the same manner as in Example 1 except that the film was changed to a polycarbonate film. Table 4 shows the maximum bending load, bending elastic gradient and adhesive strength, the weight of the adhesive part, and the appearance of the ceiling material.

  The mechanical properties and heat insulating properties of the ceiling materials of Examples 1 to 7 show almost the same performance as Comparative Example 1 laminated with low-density polyethylene, the adhesive strength is higher than 10 N / 25 cm, and the weight as a ceiling material is reduced. And the adhesion performance was excellent. In addition, when peeled, interfacial peeling between the copolymerized polyester film and the urethane foam facilitates separation into a polyester component and a urethane component, and is extremely excellent in recyclability.

  In Comparative Examples 1 and 2, since the material is polyethylene, the adhesive strength is low. In Comparative Example 1, when the coating thickness is 400 μm in order to obtain sufficient strength, the weight of the adhesive is 360 g / m 2 and the ceiling is high. The material became heavy. In Comparative Example 2, when the coating thickness was 50 μm, the adhesive strength was insufficient.

  In Comparative Example 3, since the melting point of the copolyester resin was high, the bonding temperature was high, and the urethane foam and the polyester nonwoven fabric contracted, resulting in a dirty appearance.

  In Comparative Example 4, since the copolyester film was thin, the adhesive strength was insufficient.

  In Comparative Example 5, the weight of the ceiling material became heavy because the thickness of the copolyester film was large.

In Comparative Example 6, the adhesive strength was insufficient because the adhesive was 50 μm polycarbonate.

Claims (4)

A method of laminating a ceiling material in which a skin material is laminated on one or both sides of a core material, wherein the core material is a plate material made of polymer resin foam, and a copolymer polyester film adhesive material is sandwiched between the core material and the skin material A method for laminating a ceiling material, characterized by thermocompression bonding. The method for laminating a ceiling material according to claim 1, wherein the core material is urethane foam. The copolyester film adhesive material is made of a copolyester resin having a number average molecular weight of 10,000 or more, a melting point of 70 ° C. to 150 ° C., an inorganic compound content of 5% by mass or less, and a thickness of 25 to 200 μm. The method for laminating a ceiling material according to claim 1 or 2. The ceiling material manufactured with the lamination | stacking method of the ceiling material of Claims 1-3.